Pocket door assembly



P 1968 R. F. ANDERSON POCKET DOOR ASSEMBLY 3 Sheets-Sheet 1 Filed Oct.14, 1966 I I\ I\\\ p 10, 1968 R. F. ANDERSON POCKET DOOR ASSEMBLY 3Sheets-Sheet 2 Filed Oct. 14, 1966 P 8 R. F. ANDERSON 3,400,490

POCKET DOOR ASSEMBLY Filed Oct. 14, 1966 3 Sheets-Sheet 5 United StatesPatent 3,400,490 POCKET DOOR ASSEMBLY Ralph F. Anderson, Rockford, Ill.,assignor to National Lock Co., Rockford, 111., a corporation of DelawareFiled Oct. 14, 1966, Ser. No. 586,867 4 Claims. (Cl. 49-372) ABSTRACT OFTHE DISCLOSURE A sliding door assembly where the door slides into andout of a pocket formed in the adjacent wall supported on an overheadtrack and having a rough frame for the doorway and pocket including ahorizontal bridging member between vertical frame members defining theinner end of the pocket and the outer edge of the door opening; and theoverhead elongated door track is secured to hangers which are in turnsecured to the bridging member. The track includes a horizontal flatplate having a central depending elongated J-shaped track and dependingparallel flanges spaced from the track to position nailing strips abovethe door opening. Vertical split studs formed of metal with wood insertsdefining the pocket opening for the door are secured at their upper endsto the bridging member and at their lower ends to the floor; the studsterminating at their lower ends in inturned flanges having irregularnesting peripheries. The door is mounted on a pair of hanger bracketscarrying rollers riding in the J- shaped track, the brackets havingdepending flanges secured to the face of the door adjacent the upperedge; and one bracket has a plastic adjusting wheel in a lower bracketportion cooperating with a depending adjusting screw having a threadcutting end mounted on the upper hanger racket portion for adjustment ofthe door in the opening therefor.

The present invention relates to a pocket door assembly and moreparticularly to a sliding door assembly where a sliding door is movableinto and out of a side pocket provided in the wall adjacent the frame ofthe door.

Among the objects of the present invention is the provision of a slidingdoor movable into a side pocket in a wall adjacent the door frame whichis easily and simply removed and replaced in the case of warpage ordamage without the necessity of removal of trim boards of the doorframe. The door is provided with a pair of top roller bracketassemblies, one being vertically adjustable, which are mounted on thesame surface of the door. Removing the fastening screws of thesebrackets allows the door to be swivelled in the door opening withoutremoving the brackets from the overhead track.

Another object of the present invention is the provision of a slidingdoor assembly having adjustable pairs of vertical split studs in anddefining the pocket receiving the door. The split stud is designed witha self-adjusting feature at the floor mounting area so that properclearance is obtained for the door operation. When the two studs arenailed into position, the bottom of each stud is provided with aninwardly extending flange with the shape of the flange allowing nestingto assure the necessary opening between the two studs.

A further object of the present invention is the provision of a slidingdoor assembly movable into a side pocket having split studs, and plasticguides for the door provided on the studs. The guides are applied afterthe trim strips have been secured to define the door frame making itvery easy to determine the proper door guidance for its travel in andout of the pocket.

The present invention also comprehends the provision of a sliding doorassembly cooperating with a side pocket where the door is hung on a pairof roller brackets; one

bracket being vertically adjustable. The bracket is provided with adepending adjusting screw on a roller bracket portion and an adjustingor gear type wheel on the door bracket portion. The adjusting screw isof the thread cutting type which cuts a thread in the plastic adjustingwheel assuring a tight fit therebetween to maintain any desiredadjustment.

Further objects are to provide a construction of maximum simplicity,etficiency, economy and ease of assembly and operation, and such furtherobjects, advantages and capabilities as will later more fully appear andare inherently possessed thereby.

In the drawings:

FIGURE 1 is a side elevation-a1 view partly in cross section showing thesliding door in a door frame and the adjacent wall forming the pocketfor the door.

FIG. 2 is an enlarged and broken vertical cross sectional view taken onthe line 22 of FIG. 1.

FIG. 3 is a broken side elevational view of the door and pocket hardwarewith the door frame and wall omitted.

FIG. 4 is a partial enlarged top plan view of the door track.

FIG. 5 is an end elevational view of the door track.

FIG. 6 is a front elevational view of the rear door hanger bracket.

FIG. 7 is an end elevational view of the bracket of FIG. 6.

FIG. 8 is a side elevational view of the adjustable front hangerbracket.

FIG. 9 is an end elevational view of the bracket of FIG. 8.

FIG. 10 is a horizontal cross sectional view taken on the line 10-10 ofFIG. 9.

FIG. 11 is a broken perspective view of a pair of split studs for thepocket.

Referring more particularly to the disclosure in the drawings wherein isshown an illustrative embodiment of the present invention, FIG. 1discloses a sliding door 10 adapted to provide a closure for a doorframe 11 in a wall 12; the wall containing a pocket 13 to receive thedoor 10 when it is withdrawn or retracted to provide access betweenrooms through the door frame 11. The door frame 11 includes a basicframe formed of a vertical frame member 14 opposite the pocket, and ahorizontal bridging wood insert 15 extending between the frame member 14and the vertical stud 16 defining the closed end of the pocket.

Secured to the bridging wood insert 15 are a plurality of spacedU-shaped brackets 17 each having a base portion 18 with a pair ofopenings 19 and spaced vertical arms 21, 21 having openings 22 forsuitable securing means 23 to secure the arms 21 to the sides of theinsert 15. Mounted below the insert 15 and brackets 17 is a horizontalextruded aluminum door track 24 including a generally flat member orplate 25 having spaced openings 26 adjacent each edge, dependingparallel flanges 27 and a generally centrally located depending track 28of a generally J-shape; the flanges 27 being spaced inwardly from theedges of the flat plate member 25.

Wood strips 29 are supplied with the pocket door hardware and arepositioned in the area defined by the top flat member 25 and the flanges27 as shown in FIG. 2. Suitable securing means such as screws 31 areinserted downwardly through the openings 19 and threadingly engage thealigned openings 26 by the use of Tinnerman fasteners or the like tosupport the door track 24 and, in the door frame 11, the screws 31extend through the openings 26 into and threadingly engage and securethe wood strips 29 in proper position at the top of the door frame. Boththe wood strips 29 and the door track 24 are marked at suitableintervals, such as 2-inch increments, to provide a gauge of the cut-offpoints for varying dimensions of door frame 11 (see FIGS. 3 and 4).Thus, the hardware and wood strips 29 are supplied in a standard lengthand are cut down to the desire-d size at the job site by the workmenwhen the door frame and pocket are installed.

To properly define the pocket in the wall and guide the door duringopening and closing movement, pairs of vertical split studs 33 arelocated to define the path of movement of the door in the pockets; thestuds being formed of metal and having elongated wood inserts 34 thereinwith the wood inserts of generally T-shape in cross section with the leg35 projecting outwardly from one side. The split studs 33 each include aback wall 36 with opposed side walls 37 having elongated slots 38 atspaced intervals. The side walls 37 terminate in inturned flanges 39 toform a conforming enclosure for the wood inserts 34; the leg 35 thereofextending outwardly between the flanges 39.

At the upper end of each stud 33, the back wall 36 is bent over the sidewalls 37 as at 41 and then upwardly to form a vertical offset flange 42having openings 43 to receive suitable securing means to secure theflange 42 to the bridging wood insert 15. At the lower end of the backwall 36 is provided an inturned flange 44 having an irregular nestingouter edge 45 and openings 46 for suitable securing means such as nails47 to secure the flange to the floor 48 below the pocket. The flanges 44of a pair of opposed split studs 33 are of such length as to nesttogether to assure the necessary opening between the two studs formovement of the door 10.

To allow movement of the door into and out of the pocket, the door isprovided with front and rear hanger bracket assemblies having rollerswhich move in the depending track 28 of the door track 24. The frontbracket assembly 49 (FIGS. 8 to 10) includes a front bracket 51 having avertical mounting portion 52 with openings 53 for suitable securingmeans, such as screws 54, to secure the bracket to the door 10. Ahorizontal portion 55 is formed at right angles to the vertical portionover the top edge 56 of the door 10 and spaced from the top edge bydepending ears 57 integral with the horizontal portion 55. The portion55 is provided with a centrally positioned enlarged opening 58 for anadjusting wheel 61, and reinforcing ribs 59 are formed at the junctureof the vertical and horizontal portions 52, 55.

The adjusting wheel 61 has a central hub 62 defining a central opening63 and a fluted or toothed periphery 64 for ease of adjustment. Thewheel 61 is positioned between the horizontal portion 55 of bracket 51and the top edge 56 of the door with the central hub 62 extending intothe opening 58 in the horizontal portion 55 of bracket 51 to provide anaxis of rotation for the wheel. Aligned with the opening 58 in thehorizontal portion 55 is an opening 65 into the top edge 56 of the door10.

The front bracket assembly 49 further includes a front hanger bracket 66having a horizontal flange 67 with a central opening 69 adapted toreceive an adjusting screw 71 having a thread cutting lower end 72,threaded shank 73 and a cylindrical end 74 with a radial flange 75. Thesmooth cylindrical end 74 is inserted into the opening 69 with theflange 75 positioned below the horizontal flange '67 of the bracket 66,and the portion of the end 74 extending above the flange 67 being stakedonto the flange. The cutting end 72 enters the opening 63 in the wheel61 and cuts threads into and is in threaded engagement with theadjusting wheel and extends downward into the opening 65 in the door.The wheel 61 is formed of a suitable relatively soft material, such asnylon, which will allow for ease of cutting the threads thereinto.

A vertical flange 76 of the bracket 66 has an offset upper portion witha central opening 77 for a roller rivet 78 carrying a roller 79 whichrolls in the generally 1- shaped track 28 as seen in FIG. 2. Reinforcingribs 81 are provided at the juncture of the horizontal and verticalflanges 67 and 76, respectively. It can be seen that rotation of theadjusting wheel 61 relative to the adjusting screw 71 will providevertical adjustment of the distance between the door bracket 51 and thehanger bracket 66.

The rear bracket assembly 82 (FIGS. 6 and 7) includes a verticalmounting portion 83 having openings 84 for suitable securing means, ahorizontal portion or ledge 85 adapted to contact the upper edge 56 ofthe door 10, and a vertical upper flange or portion 86 having an offsetupper end 87 with an opening 88 therein. The opening 88 receives aroller rivet 89 carrying a second roller 90 moving in the dependingtrack 28. A strengthening or reinforcing rib 91 is formed at thejuncture of the horizontal portion 84- and the upper portion 85.

When the bracket 17 and door track 24 have been installed on thebridging wood insert 15 and the split studs 33 have been secured to theinsert 15 and the floor 48 through the flanges 42 and 44, front and rearbracket assemblies 49 and 82 are installed on the door 10 and hung onthe track 28 to hang the door 10 in position. A resilient bumper 92 issecured to the vertical stud 16 to cushion movement of the door 10 intothe pocket 13. Then horizontal wood trim strips 93 are secured to theunderside of wood strips 29 and vertical wood trim strips 94 arepositioned abutting the split studs 33 forming the edge of the pocket.Then dry wall 95 can be applied and finished to form the wall around thedoor frame 11 and covering and enclosing the pocket 13, and the woodmoulding strips 96 around the frame 11 and the base moulding strips 97and quarter round or other edging strips 98 applied at the base of thewall as seen in FIG. 1. Also right angle bottom door guides 99 having amounting opening 101 in each face can be secured to the trim strips 94by suitable securing means, such as screws 102, to guide the movement ofthe lower portion of the door 19.

As seen in FIGS. 1 and 2, the openings 84 in the rear bracket assembly82 and the openings 53 on the front door bracket 51 are all exposedbelow the trim strips 93 so that the screws can be removed and the doortaken out of the frame 11 without removal of any trim boards. Thusreplacement of the door 10 because of warpage or damage thereto iseasily effected. Also, access may easily be obtained to the adjustingwheel by a screwdriver or other narrow tool with the door 10 in openposition to adjust the position of the door. As adjustments are normallyminor, only the front bracket assembly 49 is made adjustable. Theplastic wheel 61 and cutting adjustment screw 71 provide a tight fit forpositive holding in an adjusted position. Further, the guides 99 areapplied after the trim strips 94 are installed making it easy to applythe guides for determining the proper door guidance for its travel.

Having thus disclosed the invention, I claim:

1. A sliding door assembly mounted in a door frame for reciprocationinto and out of a pocket formed in the adjacent wall, comprising anelongated track horizontally extending within the door frame and thepocket in the adjacent wall and including a relatively wide flatelongated plate having a central depending and longitudinally extendingJ-shaped track and a pair of elongated depending flanges parallel to andspaced from said J-shaped track and spaced inwardly from thelongitudinal edges of the plate, a plurality of U-shaped bracketsremovably secured to and supporting said track plate, a sliding dooradapted to close the opening defined by the door frame, an adjustablefront hanger bracket assembly and a rear hanger bracket, each having ahorizontal flange parallel to the upper edge of the door and a dependingmounting flange secured to a face of the door, both said front hangerbracket assembly and said rear hanger bracket each carrying a roller atits upper end riding in said J-shaped track, wood nailing strips adaptedto be located abutting the lower surface of said track plate and theouter surface of a depending flange of the track, said wood strips beingsecured to said track plate, at least one pair of opposed split studsdefining the wall pocket and having a generally channel shape, a woodinsert for each of said split studs, each stud having a verticalmounting flange at the upper end and an inwardly extending horizontalflange at the lower end thereof secured to the floor, and a bridgingwood insert defining the upper surface of the door opening and pocket,said upper flanges of the split studs and said U-shaped brackets beingsecured to said bridging insert.

2. A sliding door assembly as set forth in claim 1, in which saidelongated track and said wood nailing strips are marked at intervals toprovide cut-off points therefor for varying door and frame dimensions.

3. A sliding door assembly as set forth in claim 1, in which said lowerhorizontal flanges on said split studs have identical irregularperipheries which, when one is reversed and facing the other, arecomplementary and adjustably nest together.

4. A sliding door assembly as set forth in claim 1, in which saidadjustable front hanger bracket assembly includes a door bracket havingsaid vertical mounting flange and said horizontal flange having acentral opening therein, a pair of depending ears on said horizontalflange abutting the top edge of the door and spacing said horizontalflange thereabove, a plastic adjusting wheel having a fluted peripherypositioned between the top edge of the door and the horizontal flangeand having a central hub extending into the central opening in saidhorizontal flange, said wheel and hub having a passage extending axiallytherethrough, and a front hanger bracket carrying said roller at theupper end thereof and having a horizontal flange at its lower end and adepending adjusting screw staked in said last mentioned horizontalflange and having a thread-cutting lower end such that said screw cutsthe threads in the axial passage in the adjusting wheel to provide apositive retaining engagement therebetween in any adjusted position,said door having an opening in the top edge aligned with the passage inthe adjusting wheel to receive the depending end of said adjustingscrew.

References Cited UNITED STATES PATENTS 2,761,172 9/1956 Jorgensen et al16-105 2,818,608 1/1958 Lawrence 49-372 XR 3,058,174 10/1962 Sterling49-372 KENNETH DOWNEY, Primary Examiner.

